Sleep system

ABSTRACT

Sleep systems and devices including a mattress conversion device and a mattress are disclosed. The mattress conversion device includes a base layer, one or more side portions, and a cavity defined by the base layer and the one or more side portions. The mattress conversion device can slidingly received the mattress. A method for recycling an existing mattress is also disclosed.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/827,447, entitled “Mattress Size Converter”, filed Apr. 1, 2019, the content of which is incorporated by reference in its entirety.

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/916,314, entitled “Sleep System”, filed Oct. 17, 2019, the content of which is incorporated by reference in its entirety.

FIEL_(D) OF THE INVENTION

The present invention relates generally to a sleep system including a mattress. More particularly, the present invention relates to a device for converting one mattress size into a second mattress size, and a corresponding mattress frame.

BACKGROUND

Mattresses are used across the globe to support the human body while sleeping. Conventional mattresses are costly, and are expected to last a decade or longer. In some situations, a mattress is purchased of a certain size and/or type, and at some time later a different size and/or type mattress is desired. There is a need for mattresses or mattress conversion kits to economically deal with this issue.

SUMMARY

According to one aspect of the present inventive concepts, a sleep system comprises a mattress and a mattress conversion device comprising a base layer, one or more side portions, and a cavity defined by the base layer and the one or more side portions. The mattress conversion device can be configured to slidingly receive the mattress.

In some embodiments, the mattress conversion device slidingly receives the mattress via the cavity. The mattress conversion device base layer can be positioned proximate a first surface of the mattress and at least one mattress conversion device side portion can be positioned proximate a second surface of the mattress.

In some embodiments, the mattress conversion device base layer comprises a length of at least 75 inches, a width of at least 38 inches, and/or a depth of at least 7 inches. The mattress conversion device base layer can comprise a length similar to a length of the mattress. The mattress conversion device base layer can comprise a length greater than a length of the mattress. The mattress conversion device base layer can comprise a width greater than a width of the mattress.

In some embodiments, at least one mattress conversion device side portion comprises a length of at least 75 inches, a width of at least 3 inches, and/or a depth of at least 7 inches. Two or more mattress conversion device side portions can comprise similar lengths, widths, and/or depths. Two or more mattress conversion device side portions can comprise dissimilar lengths, widths, and/or depths. At least one mattress conversion device side portion can comprise a length similar to a length of the mattress. At least one mattress conversion device side portion can comprise a length greater than a length of the mattress. At least one mattress conversion device side portion can comprise a depth similar to a depth of the mattress. At least one mattress conversion device side portion can comprise a depth less than a depth of the mattress.

In some embodiments, the mattress comprises a twin mattress. The mattress conversion device can be configured to convert the twin mattress into a full mattress. The mattress conversion device can be configured to increase a width of the twin mattress by at least 8 inches, such as at least 15 inches.

In some embodiments, the mattress comprises an extra-long twin mattress. The mattress conversion device can be configured to convert the extra-long twin mattress into an extra-long full mattress. The mattress conversion device can be configured to increase a width of the extra-long twin mattress by at least 8 inches, such as at least 15 inches.

In some embodiments, the mattress comprises a full mattress. The mattress conversion device can be configured to convert the full mattress into a queen mattress. The mattress conversion device can be configured to increase a width of the full mattress by at least 7 inches and increase a length of the full mattress by at least 5 inches.

In some embodiments, the mattress comprises a queen mattress. The mattress conversion device can be configured to convert the queen mattress into a king mattress. The mattress conversion device can be configured to increase a width of the queen mattress by at least 16 inches.

In some embodiments, the mattress conversion device comprises a material selected from the group consisting of: foam; latex; polyester; polyester blend; wool; cotton; and combinations thereof.

In some embodiments, the system can further comprise a frame conversion device. The frame conversion device can be configured to provide support to at least one mattress conversion device or mattress. The frame conversion device can be configured to removably attach to a bed frame. The frame conversion device can be removably attached to the bed frame via one or more attachment assemblies.

In some embodiments, the system can further comprise a mattress storage device. The mattress storage device can be configured to store at least one mattress conversion device or mattress. The mattress storage device can comprise an enclosure comprising one or more fluid exchange ports.

In some embodiments, the system can further comprise a mattress transport assembly. The mattress transport assembly can be configured to secure at least one mattress conversion device or mattress to a vehicle.

According to another aspect of the present inventive concepts, a method for recycling an existing mattress comprises acquiring an existing mattress, disassembling the existing mattress into two or more portions, and creating at least a portion of a new mattress using at least one portion of the existing mattress. The method can further comprise testing the existing mattress for defects and/or other desirable features prior to disassembling the existing mattress. The method can further comprise evaluating the existing mattress based on a defect threshold. The method can further comprise creating at least a portion of a mattress conversion device using at least one portion of the existing mattress. The method can further comprise recycling at least one portion of the existing mattress. The method can further comprise discarding at least one portion of the existing mattress.

According to another aspect of the present inventive concepts, a process for repurposing an existing mattress comprises dividing a first existing mattress into at least two portions, dividing a second existing mattress into at least two portions, and combining at least one portion of the first existing mattress with at least one portion of the second existing mattress. The combined portions of the first and second existing mattresses can produce at least one portion of at least one new mattress. The process can be configured to produce the new mattress while discarding less than 25% of each existing mattress. The process can be configured to produce the new mattress while discarding less than 20% of each existing mattress. The process can be configured to produce the new mattress while discarding Less than 15% of each existing mattress. The process can be configured to produce the new mattress while discarding less than 10% of each existing mattress. The first and second existing mattresses can each comprise a queen mattress divided into at least two portions, and at least one portion of each existing mattress can be combined to produce at least three new extra-long twin mattresses. The first and second existing mattresses can be each divided into a first portion comprising a width of 38 inches and a second portion comprising a width of 22 inches. The first portion of the first existing mattress can comprise a first new extra-long twin mattress, the first portion of the second existing mattress can comprise a second new extra-long twin mattress, and the second portions of the first and second existing mattresses can be combined to produce a third new extra-long twin mattress. The combining of the at least one portion of the first existing mattress with the at least one portion of the second existing mattress can comprise bonding the portions together.

Incorporation by Reference

All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. The content of all publications, patents, and patent applications mentioned in this specification are herein incorporated by reference in their entirety for all purposes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exploded view of a sleep system including a mattress conversion device, consistent with the present inventive concepts.

FIGS. 2A-C illustrate an exploded view, a partially exploded view, and a perspective view, respectively, of a mattress conversion device, consistent with the present inventive concepts.

FIGS. 3A-C illustrate an exploded view, a perspective view, and a front view, respectively, of a mattress conversion device, consistent with the present inventive concepts.

FIGS. 4A-B illustrate a top perspective view and a bottom perspective view, respectively, of a mattress support device removably attached to a bed frame, consistent with the present inventive concepts.

FIGS. 5, 5A, and 5B illustrate a schematic view, a first perspective view, and a second perspective view, respectively, of a portion of a support device, consistent with the present inventive concepts.

FIGS. 6, 6A, and 6B illustrate a side view, a close-up perspective view, and a side sectional view of a plank including at attachment assembly, consistent with the present inventive concepts.

FIGS. 7A-B illustrate a top perspective view and a bottom perspective view, respectively, of a support device removably attached to a bed frame, consistent with the present inventive concepts.

FIGS. 8A-B illustrate a close-up perspective view and a side sectional view, respectively, of a plank including an attachment assembly, consistent with the present inventive concepts.

FIGS. 9, 9A, and 9B illustrate a schematic view, a first perspective view, and a second perspective view, respectively, of a portion of a support dive including a lateral support assembly, consistent with the present inventive concepts.

FIGS. 10A-D illustrate a perspective view, a partial close-up view, a first side view and a second side view, respectively, of a mattress transport assembly, consistent with the present inventive concepts.

FIGS. 11A-C illustrate a side view and two side perspective views, respectively, of a mattress storage device including a mattress, consistent with the present inventive concepts.

FIG. 12 illustrates a flow chart of a method for processing a previously manufactured mattress to produce a new mattress, consistent with the present inventive concepts.

FIG. 13A illustrates a close-up perspective view of a bracket of a support device, consistent with the present inventive concepts.

FIG. 13B illustrates a top perspective view of a support device, consistent with the present inventive concepts.

FIGS. 14A-C illustrate a series of component configurations in a manufacturing process for repurposing previously manufactured mattresses, consistent with the present inventive concepts.

DETAILED DESCRIPTION OF THE DRAWINGS

Reference will now be made in detail to the present embodiments of the technology, examples of which are illustrated in the accompanying drawings. Similar reference numbers may be used to refer to similar components. However, the description is not intended to limit the present disclosure to particular embodiments, and it should be construed as including various modifications, equivalents, and/or alternatives of the embodiments described herein.

It will be understood that the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

It will be further understood that, although the terms first, second, third, etc. may be used herein to describe various limitations, elements, components, regions, layers and/or sections, these limitations, elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one limitation, element, component, region, layer or section from another limitation, element, component, region, layer or section. Thus, a first limitation, element, component, region, layer or section discussed below could be termed a second limitation, element, component, region, layer or section without departing from the teachings of the present application.

It will be further understood that when an element is referred to as being “on”, “attached”, “connected” or “coupled” to another element, it can be directly on or above, or connected or coupled to, the other element, or one or more intervening elements can be present. In contrast, when an element is referred to as being “directly on”, “directly attached”, “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g. “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).

It will be further understood that when a first element is referred to as being “in”, “on” and/or “within” a second element, the first element can be positioned: within an internal space of the second element, within a portion of the second element (e.g. within a wall of the second element); positioned on an external and/or internal surface of the second element; and combinations of one or more of these.

As used herein, the term “proximate”, when used to describe proximity of a first component or location to a second component or location, is to be taken to include one or more locations near to the second component or location, as well as locations in, on and/or within the second component or location. For example, a component positioned proximate an anatomical site (e.g. a target tissue location), shall include components positioned near to the anatomical site, as well as components positioned in, on and/or within the anatomical site.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like may be used to describe an element and/or feature's relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be further understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in a figure is turned over, elements described as “below” and/or “beneath” other elements or features would then be oriented “above” the other elements or features. The device can be otherwise oriented (e.g. rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The terms “reduce”, “reducing”, “reduction” and the like, where used herein, are to include a reduction in a quantity, including a reduction to zero. Reducing the likelihood of an occurrence shall include prevention of the occurrence. Correspondingly, the terms “prevent”, “preventing”, and “prevention” shall include the acts of “reduce”, “reducing”, and “reduction”, respectively.

The term “and/or” where used herein is to be taken as specific disclosure of each of the two specified features or components with or without the other. For example “A and/or B” is to be taken as specific disclosure of each of (i) A, (ii) B and (iii) A and B, just as if each is set out individually herein.

The term “one or more”, where used herein can mean one, two, three, four, five, six, seven, eight, nine, ten, or more, up to any number.

The terms “and combinations thereof” and “and combinations of these” can each be used herein after a list of items that are to be included singly or collectively. For example, a component, process, and/or other item selected from the group consisting of: A; B; C; and combinations thereof, shall include a set of one or more components that comprise: one, two, three or more of item A; one, two, three or more of item B; and/or one, two, three, or more of item C.

In this specification, unless explicitly stated otherwise, “and” can mean “or”, and “or” can mean “and”. For example, if a feature is described as having A, B, or C, the feature can have A, B, and C, or any combination of A, B, and C. Similarly, if a feature is described as having A, B, and C, the feature can have only one or two of A, B, or C.

As used herein, when a quantifiable parameter is described as having a value “between” a first value X and a second value Y, it shall include the parameter having a value of: at least X, no more than Y, and/or at least X and no more than Y. For example, a length of between 1 and 10 shall include a length of at least 1 (including values greater than 10), a length of less than 10 (including values less than 1), and/or values greater than 1 and less than 10.

The expression “configured (or set) to” used in the present disclosure may be used interchangeably with, for example, the expressions “suitable for”, “having the capacity to”, “designed to”, “adapted to”, “made to” and “capable of” according to a situation. The expression “configured (or set) to” does not mean only “specifically designed to” in hardware. Alternatively, in some situations, the expression “a device configured to” may mean that the device “can” operate together with another device or component.

As used herein, the term “threshold” refers to a maximum level, a minimum level, and/or range of values correlating to a desired or undesired state. In some embodiments, a system parameter is maintained above a minimum threshold, below a maximum threshold, within a threshold range of values, and/or outside a threshold range of values, such as to cause a desired effect (e.g. a good night's sleep) and/or to prevent or otherwise reduce (hereinafter “prevent”) an undesired event (e.g. a bad night's sleep). In some embodiments, a system parameter is maintained above a first threshold and below a second threshold. In some embodiments, a threshold value is determined to include a safety margin, such as to account for user variability, system variability, tolerances, and the like. As used herein, “exceeding a threshold” relates to a parameter going above a maximum threshold, below a minimum threshold, within a range of threshold values and/or outside of a range of threshold values.

The term “diameter” where used herein to describe a non-circular geometry is to be taken as the diameter of a hypothetical circle approximating the geometry being described. For example, when describing a cross section, such as the cross section of a component, the term “diameter” shall be taken to represent the diameter of a hypothetical circle with the same cross sectional area as the cross section of the component being described.

The terms “major axis” and “minor axis” of a component where used herein are the length and diameter, respectively, of the smallest volume hypothetical cylinder which can completely surround the component.

As used herein, the term “functional element” is to be taken to include one or more elements constructed and arranged to perform a function. A functional element can comprise a sensor and/or a transducer. In some embodiments, a functional element is configured to deliver energy. Alternatively or additionally, a functional element (e.g. a functional element comprising a sensor) can be configured to record one or more parameters, such as a user physiologic parameter; a user anatomical parameter; a patient environment parameter; and/or a system parameter. In some embodiments, a sensor or other functional element is configured to perform a diagnostic function (e.g. to gather data used to perform a diagnosis). In some embodiments, a functional element is configured to perform a therapeutic function (e.g. to deliver therapeutic energy and/or a therapeutic agent). In some embodiments, a functional element comprises one or more elements constructed and arranged to perform a function selected from the group consisting of: deliver energy; extract energy (e.g. to cool the user or a system component); deliver a drug or other agent; record or otherwise sense a parameter such as a user physiologic parameter or a system parameter; and combinations of one or more of these. A functional element can comprise a fluid and/or a fluid delivery system. A functional element can comprise a reservoir, such as an expandable balloon or other fluid- maintaining reservoir. A “functional assembly” can comprise an assembly constructed and arranged to perform a function, such as a diagnostic and/or therapeutic function. A functional assembly can comprise one or more functional elements.

The term “transducer” where used herein is to be taken to include any component or combination of components that receives energy or any input, and produces an output. In some configurations, a transducer converts an electrical signal into any output, such as: light (e.g. a transducer comprising a light emitting diode or light bulb), sound (e.g. a transducer comprising a piezo crystal configured to deliver ultrasound energy); pressure (e.g. an applied pressure or force); heat energy; cryogenic energy; chemical energy; mechanical energy (e.g. a transducer comprising a motor or a solenoid); magnetic energy; and/or a different electrical signal (e.g. different than the input signal to the transducer). Alternatively or additionally, a transducer can convert a physical quantity (e.g. variations in a physical quantity) into an electrical signal. A transducer can include any component that delivers energy and/or an agent to a user and/or a component of the system, such as a transducer configured to deliver one or more of: electrical energy (e.g. a transducer comprising one or more electrodes); light energy (e.g. a transducer comprising a laser, light emitting diode and/or optical component such as a lens or prism); mechanical energy; sound energy (e.g. a transducer comprising a piezo crystal); chemical energy; electromagnetic energy; magnetic energy; and combinations of one or more of these. In some embodiments, a transducer is configured to deliver energy to improve the user's sleep and/or to treat a medical condition of the user.

As used herein, the term “fluid” can refer to a liquid, gas, gel, or any flowable material, such as a material which can be propelled through a lumen and/or opening.

As used herein, the term “material” can refer to a single material, or a combination of two, three, four, or more materials.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. For example, it will be appreciated that all features set out in any of the claims (whether independent or dependent) can be combined in any given way.

It is to be understood that at least some of the figures and descriptions of the invention have been simplified to focus on elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention. However, because such elements are well known in the art, and because they do not necessarily facilitate a better understanding of the invention, a description of such elements is not provided herein.

Terms defined in the present disclosure are only used for describing specific embodiments of the present disclosure and are not intended to limit the scope of the present disclosure. Terms provided in singular forms are intended to include plural forms as well, unless the context clearly indicates otherwise. All of the terms used herein, including technical or scientific terms, have the same meanings as those generally understood by an ordinary person skilled in the related art, unless otherwise defined herein. Terms defined in a generally used dictionary should be interpreted as having meanings that are the same as or similar to the contextual meanings of the relevant technology and should not be interpreted as having ideal or exaggerated meanings, unless expressly so defined herein. In some cases, terms defined in the present disclosure should not be interpreted to exclude the embodiments of the present disclosure.

Referring now to FIG. 1, an exploded view of a sleep system including a mattress conversion device is illustrated, consistent with the present inventive concepts. System 10 can comprise a mattress 60 and a mattress conversion device 100. Mattress 60 can comprise a king-sized mattress, a queen sized mattress, an extra-long twin mattress, twin mattress, or any other sized mattress. Mattress conversion device 100 can be configured to surround at least a portion of mattress 60, such as to provide an increased sleep surface. System 10 can further comprise a support structure, bed frame 70. System 10 can further comprise a frame conversion device 300 configured to be removably attached to bed frame 70. Bed frame 70 and frame conversion device 300 can be configured to provide a support structure for mattress 60 and mattress conversion device 100 (e.g. mattress 60 and mattress conversion device 100 are positioned on top of frame conversion device 300, which is attached to bed frame 70). Various embodiments of bed frame 70 and frame conversion device 300 are described in further detail herebelow in reference to FIGS. 4A-6B, FIGS. 7A-9B, and Figs, 13A-B.

Conversion device 100 is constructed and arranged to increase the size of an existing mattress 60 while also increasing the comfort of mattress 60. The market currently provides mattress conversion systems that are designed for scenarios in which two mattresses are pushed together to create a large mattress, and the conversion system provides an element to cover the space (e.g. crack, depression) between the two mattresses to create a uniform surface over the two mattresses. Conversion device 100 as disclosed herein is constructed and arranged to allow an existing mattress to remain where it is positioned relative to a bed frame and/or other furniture, which has been identified as a priority for institutions (e.g. an educational institution, such as a university or college) that provide a mattress and/or other furniture for use by an individual.

Conversion device 100 can comprise a base portion 120 comprising a base layer 121 and at least one side portion 122, such as two side portions 122 a,b shown. Base layer 121 and side portions 122 a,b can define a cavity 125. Each side portion 122 can comprise one, two, or more discrete elements (e.g. two or more foam pieces positioned relative to each other). In some embodiments, only one of side portion 122 a or 122 b is included.

In some embodiments, conversion device 100 further comprises a top layer 110 configured to be positioned on top of base layer 121. Conversion device 100 can be configured to receive mattress 60 via cavity 125. Conversion device 100 including mattress 60 can be positioned on top of frame conversion device 300 and/or frame 70. Conversion device 100 is described in further detail herebelow in reference to FIGS. 2A-3C.

Bed frame 70 can comprise a plurality of legs 71, rails 72, and cross members 73. Legs 71 can be configured to elevate rails 72 and cross members 73 off of a surface (e.g. above a floor). Rails 72 can be configured to provide support along a length of bed frame 70. Rails 72 can be fixedly attached to legs 71 during a manufacturing process. Alternatively, rails 72 and legs 71 can comprise a single piece (e.g. comprise a single component) created during a manufacturing process. In some embodiments, legs 71 are configured to extend above rails 72. In some embodiments, at least two sets of rails 72 are fixedly attached to a single leg 71 at different locations. Cross members 73 can be configured to provide support between rails 72. Cross members 73 can be fixedly attached to rails 72 during a manufacturing process. Alternatively, cross members 73 and rails 72 can comprise a single piece constructed during a manufacturing process.

System 10 can comprise one or sensors, transducers, devices, and/or other functional elements, as described herein, such as functional elements 69, 79, 99, 199, and/or 399 shown. One or more functional elements 69, 79, 99, 199, and/or 399 can be configured to cooperatively function with one or more others of functional elements 69, 79, 99, 199, and/or 399, such as to transfer control signals, sensor data, and/or other information between them. Functional element 69, 79, 99, 199, and/or 399 can comprise a device configured to perform a function, such as to provide an alert or other information to a user of system 10. Functional element 69, 79, 99, 199, and/or 399 can comprise a sensor assembly that includes one or more sensors and associated electronics to interface with the one or more sensors and to provide (e.g. wirelessly or via a wired connection) information related to one or more parameters monitored by the one or more sensors. Functional element 69, 79, 99, 199, and/or 399 can comprise a transducer assembly configured to perform an action, such as to vibrate, move, change the temperature of, and/or otherwise modify itself and/or another component of system 10.

In some embodiments, functional element 99 comprises a device that receives information or otherwise interfaces with one or more functional elements 69, 79, 199, and/or 399 that comprise a sensor- based functional element. For example, functional element 69, 79, 199, and/or 399 can comprise a sensor or sensor assembly (“sensor” herein) configured to monitor an environmental parameter and/or a user parameter (e.g. a user sleeping or other interfacing with system 10) and functional element 99 can comprise a device that receives information from the sensor. Functional element 69, 79, 99, 199, and/or 399 can comprise a sensor configured to monitor an environmental parameter selected from the group consisting of: oxygen level, carbon dioxide level; carbon monoxide level; radon level; temperature; pressure; humidity; and combinations of these. Alternatively or additionally, functional element 69, 79, 99, 199, and/or 399 can comprise a sensor configured to monitor a user parameter selected from the group consisting of: sleep state; presence of user in bed (e.g. on mattress 60); heart rate; respiration rate; blood pressure; temperature; and combinations of these. In some embodiments, functional element 69, 79, 99, 199, and/or 399 provides a signal related to a patient being in bed, such as a patient with dementia or other neurological disorder. In these embodiments, system 10 can provide an alarm if the patient leaves their bed at an undesired time.

Functional element 69, 79, 99, 199, and/or 399 can comprise a transducer or transducer assembly (“transducer” herein) that is configured to alert the patient, such as when an undesired environmental or user condition is detected (e.g. by a sensor-based functional element of system 10 as described herein). Functional element 69, 79, 99, 199, and/or 399 can comprise a transducer that alerts the user by: producing an alert sound (e.g. via a speaker), producing light (e.g. via a light emitting diode), and/or shaking the user (e.g. via a vibrational transducer or mechanical assembly).

Referring now to FIGS. 2A-C, an exploded view, a partially exploded view, and a perspective view of a mattress conversion device are illustrated, respectively, consistent with the present inventive concepts. As described hereabove, mattress conversion device 100 can comprise top layer 110 and base portion 120 comprising base layer 121 and side portions 122 a,b. Base layer 121 and side portions 122 a,b can comprise discrete components, as shown in FIG. 2A, such as discrete components that are joined or otherwise connected during a manufacturing process to form base portion 120. For example, side portions 122 a,b can be adhered to base layer 121 to form base portion 120. Alternatively, base portion 120 can comprise a unity construction such as a single piece from which cavity 125 has been formed (e.g. via removal of material) in a manufacturing process. In other embodiments, base portion 120 can be manufactured in accordance with a process selected from the group consisting of: a molding process; a material removal process; an assembly process (e.g. the assembly of one or more discrete components to form base portion 120); and combinations of two or more of these.

Base portion 120 (e.g. base layer 121 and/or side portions 122) can comprise a material selected from the group consisting of: foam; latex; polyester; polyester blend; wool; cotton; and combinations of two or more of these. In some embodiments, top layer 110 comprises a material similar to base portion 120. In some embodiments, top layer 110 comprises a material dissimilar to base portion 120. For example, top layer 110 can comprise a more expensive material than base portion 120. As another example, top layer 110 can comprise a softer material than base portion 120.

Referring additionally to FIG. 3A, an exploded view including the dimensions of mattress conversion device 100 and mattress 60 is illustrated, consistent with the present inventive concepts. Mattress 60 comprises a length L_(M), a width W_(M), and a depth D_(M). Mattress 60 can further comprise a first surface 61 and a second surface 62. Mattress 60 can comprise a length L_(M) of at least 51 inches, such as at least 75 inches. Mattress 60 can comprise a width W_(M) of at least 27 inches, such as at least 38 inches. Mattress 60 can comprise a depth D_(M) of at least 4 inches, such as at least 7 inches.

Mattress conversion device 100 comprises a length L_(D) (e.g. the length of top layer 110, base layer 121, side portion 122), a width W_(D) (e.g. the width of top layer 110, base layer 121), and a depth DD. Length L_(D) can comprise a length of at least 75 inches, such as at least 80 inches. In some embodiments, length L_(D) is similar to length L_(M) of mattress 60. In other embodiments, length L_(D) is greater than length L_(M) of mattress 60. Width W_(D) can comprise a width of at least 38 inches, such as at least 46 inches, such as at least 54 inches. In some embodiments, width W_(D) is greater than width W_(M) of mattress 60, such as at least 8 inches greater, such as at least 15 inches greater. Depth D_(D) can comprise the collective depths of top layer 110, base layer 121, and/or side portion 122. Depth D_(D) can comprise a depth of at least 7 inches, such as at least 10 inches. In some embodiments, depth D_(D) is greater than the depth D_(M) of mattress 60.

Base layer 121 comprises a length L_(B), a width W_(B), and a depth D_(B). Length L_(B) can comprise a length of at least 75 inches, such as at least 80 inches. In some embodiments, length L_(B) is similar to length L_(M) of mattress 60. In other embodiments, length L_(B) is greater than length L_(M) of mattress 60. Width WB can comprise a width of at least 38 inches, such as at least 54 inches. In some embodiments, width WB is greater than width W_(M) of mattress 60. Depth D_(B) can comprise a depth of at least 1 inch, such as least 2 inches.

Each side portion 122 comprises a length L_(S), a width W_(S), and a depth D_(S). Length L_(S) can comprise a length of at least 12 inches, such as at least 15 inches. Width W_(S) can comprise a width of at least 3 inches, such as at least 4 inches. Depth D_(S) can comprise a depth of at least 7 inches, such as at least 10 inches. In some embodiments, depth D_(S) is similar to depth D_(M) of mattress 60. Two or more portions 122 can comprise similar lengths L_(S), widths W_(S), and/or depths D_(S). Two or more side portions 122 can comprise dissimilar lengths L_(S), widths W_(S), and/or depths D_(S). At least one side portion 122 can comprise a length Ls similar to a length L_(M) of mattress 60. At least one side portion 122 can comprise a length L_(S) greater than a length L_(M) of mattress 60. At least one side portion 122 can comprise a depth D_(S) similar to a depth D_(M) of mattress 60. At least one mattress conversion device side portion can comprise a depth D_(S) less than a depth D_(M) of mattress 60.

Cavity 125 comprises a width W_(C) and a depth D_(C). Width W_(C) can comprise a width of at least 27 inches, such as at least 38 inches. In some embodiments, width W_(C) is similar to width W_(M) of mattress 60. Depth D_(C) can comprise a depth of at least 4 inches, such as at least 7 inches. In some embodiments, depth D_(C) is similar to depth D_(M) of mattress 60. In some embodiments, depth D_(C) is similar to depth D_(S) of at least one side portion 122.

Top layer 110 comprises a depth D_(T) comprising a depth of at least 1 inch, such as least 2 inches.

Referring additionally to FIGS. 3B and 3C, a perspective view and a front view of mattress conversion device 100 including mattress 60 are illustrated, respectively, consistent with the present inventive concepts. Mattress conversion device 100 receives mattress 60 via cavity 125, such that first surface 61 is proximate base layer 121 and second surface 62 is proximate side portion 122.

In some embodiments, mattress 60 comprises a twin mattress. Mattress conversion device 100 can be configured to convert mattress 60 into a full mattress, such as by increasing the width of mattress 60 by at least 8 inches, such as by at least 15 inches.

In some embodiments, mattress 60 comprises an extra-long mattress. Mattress conversion device 100 can be configured to convert mattress 60 into an extra-long full mattress, such as by increasing the width of mattress 60 by at least 8 inches, such as by at least 15 inches.

In some embodiments, mattress 60 comprises a full mattress. Mattress conversion device 100 can be configured to convert mattress 60 into a queen mattress, such as by increasing the width of mattress 60 by at least 7 inches and/or increasing the length of mattress 60 by at least 5 inches.

In some embodiments, mattress 60 comprises a queen mattress. Mattress conversion device 100 can be configured to convert mattress 60 into a king mattress, such as by increasing the width of mattress 60 by at least 16 inches.

Referring now to FIGS. 4A and 4B, a top perspective view and a bottom perspective view of a mattress support device removably attached to a bed frame are illustrated, respectively, consistent with the present inventive concepts. Frame conversion device 300 can comprise a plurality of support structures, planks 310. Each plank 310 can comprise a rigid material and can be configured to provide a supportive force to mattress 60 and/or mattress conversion device 100 placed thereupon. Planks 310 can be interconnected with one or more connecting members, straps 320. Straps 320 can comprise a non-rigid material, such that frame conversion device 300 can be collapsed (e.g. for storage and/or transportation). In some embodiments, straps 320 can comprise a rigid material, such as when strap 320 comprises a wooden cross beam connecting one or more planks 310.

Planks 310 can comprise at least a first plank type 310 a, comprising at least one lateral support assembly 340, and at least a second plank type 310 b, comprising at least one attachment assembly 330 (12 shown in FIG. 4A). Lateral support assembly 340 is described in detail herebelow in reference to FIGS. 5, 5A, and 5B. Attachment assembly 330 is described in detail herebelow in reference to FIGS. 6, 6A, and 6B. In some embodiments, plank 310 can comprise both one or more lateral support assemblies 340 and one or more attachment assemblies 330. Each plank 310 (plank 310 a and/or 310 b) can comprise a width WP of at least 3 inches, such as at least 7 inches. In some embodiments, planks 310 a comprise a width WP greater than planks 310 b. device 300 can comprise a width W_(S) (e.g. the length of planks 310) of at least 38 inches, such as at least 54 inches. In some embodiments, width W_(S) is greater than or equal to width W_(F) of bed frame 70. Each strap 320 can comprise a length L_(S) such that when fully extended, frame conversion device 300 comprises a length L_(S) of at least 50 inches, such as at least 54 inches. In some embodiments, the planks 310 of frame conversion device 300 can be attached to bed frame 70 while straps 320 are not fully extended, such that frame conversion device 300 can be attached to a bed frame 70 with a length less than the length L_(S).

Referring now to FIGS. 5, 5A, and 5B, a schematic view, and two perspective views of a portion of frame conversion device 300 are illustrated, respectively, consistent with the present inventive concepts. Pairs of lateral support assemblies 340 can be configured to adjustably secure plank 310 a to bed frame 70. Each lateral support assembly 340 can comprise a support member, block 341, slidingly attached to plank 310 a. Block 341 can comprise a slot 342, through which a fastening member, bolt 343, is threadedly attached to plank 310 a. As shown in FIG. 4A, plank 310 a can comprise a fastening member, nut 344, fixedly attached thereto. Bolt 343 can be threaded into nut 344, such that block 341 is slidingly attached to plank 310 a. Bolt 343 can be configured to be tightened, such as to secure the position of block 341 relative to plank 310 a, and to be loosened to allow the position of block 341 to be adjusted relative to plank 310 a.

As shown in FIGS. 5A and 5B, block 341 can be configured to be adjusted to abut a rail 72 of bed frame 70. Each plank 310 a can comprise two support assemblies 340 (e.g. one support assembly 340 proximate either end of plank 310 a), such that bed frame 70 can be secured between the two support assemblies 340. Support assemblies 340 can comprise adjustable assemblies such that bed frames 70 of varying widths can be secured therebetween. Each plank 310 a, comprising a pair of support assemblies 340, can be configured to secure to a bed frame 70 comprising a width W_(F) between 37 inches and 72 inches.

Referring now to FIG. 6, 6A, and 6B, a side view, a close-up perspective view, and a side sectional view of a plank including an attachment assembly are illustrated, respectively, consistent with the present inventive concepts. Each plank 310 b can comprise one or more attachment assemblies 330, configured to removably attach plank 310 b to a portion of bed frame 70, as described herebelow. In some embodiments, each plank 310 b comprises an attachment assembly 330 proximate each end of plank 310 b. Attachment assembly 330 can comprise a strap 331, which can be configured to pass from a top side of plank 310 b, through a first hole 316 in plank 310 b, surround a portion of a rail 72 of bed frame 70, and pass through a second hole 317 in plank 310 b back to the top side of plank 310 b. Strap 331 can be configured to secure to itself and/or the top side of plank 310 b, securing rail 72 to the bottom side of plank 310 b.

Strap 331 can comprise a first portion 332, fixedly attached to the top side of plank 310 b, such as between holes 316 and 317. Strap 331 can comprise a second portion 333, configured to surround a portion of rail 72 and secure to the top side of plank 310 b. Attachment assembly 330 can comprise an attachment portion 334, fixedly attached to the top side of plank 310 b, such as opposite hole 316 from first portion 332 of strap 331 (as shown). Second portion 333 of strap 331 can be configured to secure to first portion 332 and or attachment portion 334 to secure rail 72. In some embodiments, attachment portion 334 and/or strap 331 comprises hook and loop fasteners. Alternatively or additionally, attachment assembly 330 can comprise fastening devices selected from the group consisting of: buttons; cinch buckles; and combinations of two or more of these.

Referring now to FIGS. 7A and 7B, a top perspective view and a bottom perspective view of a support device removably attached to a bed frame are illustrated, respectively, consistent with the present inventive concepts. In some embodiments, frame conversion device 300 comprises multiple support structures, planks 410. Each plank 410 can comprise a rigid material and can be configured to provide a supportive force to a mattress 60 and/or mattress conversion device 100 placed thereupon.

Planks 410 can comprise at least one attachment assembly 330, as described herein in reference to FIGS. 6, 6A, and 6B, as well as 8, 8A, and 8B. Planks 410 can further comprise at least a portion of a lateral support assembly, assembly 420. Lateral support assembly 420 is described in detail herebelow in reference to FIGS. 9, 9A, and 9B. Planks 410 can further comprise one, two, or more openings or reduced material portions, reliefs 411 shown. Reliefs 411 can be included to reduce weight of frame conversion device 300 and/or to provide a grasping location for a user's hand (e.g. a user that is assembling frame conversion device 300).

Planks 410 can comprise a width WP of at least 38 inches, such as at least 54 inches. In some embodiments, width WP is less than or equal to the width W_(M) of mattress 60 and/or greater than or equal to the width WB of bed frame 70. Planks 410 can comprise a length L_(P) of at least 10 inches, such as at least 20 inches. Frame conversion device 300 can comprise a length L_(D) (e.g. the collective length of two or more planks 410 that are a part of frame conversion device 300) of at least 51 inches, such as at least 75 inches. In some embodiments, length L_(D) is less than or equal to the length L_(M) of mattress 60 and/or greater than or equal to the length L_(F) of bed frame 70.

Referring now to FIGS. 8A and 8B, a close-up perspective view and a side sectional view of a plank including an attachment assembly are illustrated, respectively, consistent with the present inventive concepts. Each plank 410 can comprise one or more attachment assemblies 330, configured to removably attach plank 410 to a portion of bed frame 70, as described herebelow. In some embodiments, each plank 410 comprises an attachment assembly 330 proximate each end of plank 410. Attachment assembly 330 can comprise a strap 331 configured to pass from a top side of plank 410, through a first hole 316 in plank 410, surround a portion of rail 72 of bed frame 70, and pass through a second hole 317 of plank 410 back to the top side of plank 410. Strap 331 can be configured to secure to itself and/or the top side of plank 410, securing rail 72 to the bottom side of plank 410.

Strap 331 can comprise a first portion 332, fixedly attached to the top side of plank 410, such as between holes 316 and 317. Strap 331 can comprise a second portion 333 configured to surround a portion of rail 72 and secure to the top side of plank 410. Attachment assembly 330 can comprise an attachment portion 334, fixedly attached to the top side of plank 410, such as opposite hole 316 from first portion 332 of strap 331 (as shown). Second portion 333 of strap 331 can be configured to secure first portion 332 and/or attachment portion 334 to secure rail 72. In some embodiments, attachment portion 334 and/or strap 331 comprises hook and loop fasteners. Alternatively, or additionally, attachment assembly 330 can comprise fastening devices selected from the group consisting of: buttons; cinch buckles; and combinations of two or more of these.

Referring now to FIGS. 9, 9A, and 9B, a schematic view and two perspective views of a portion of frame conversion device 300 including a lateral support assembly are illustrated, respectively, consistent with the present inventive concepts. Lateral support assembly 420 can be configured to adjustably secure at least two planks 410 to bed frame 70 as well as to secure two planks 410 to each other. Each plank 410 can comprise a portion of lateral support assembly 420, such that neighboring planks 410 a, b coordinate to comprise a single lateral support assembly 420.

Each plank 410 can comprise a first slot grid, grid 421 a, and a second slot grid, grid 421 b. Each slot grid 421 a, b can comprise a plurality of slots 422, such as slots 422 a-d. Slots 422 a comprises a pair of slots (two openings), slot 422 a′ and 422 a″, slot 422 b comprises slots 422 b′ and 422 b″, slot 422 c comprises slots 422 c′ and 422 c″, and slot 422 d comprises slots 422 d′ and 422 d″, each as shown. Slot grid 421 a of plank 410 a can be constructed and arranged to align with slot grid 421 b of plank 410 b. For example, slot 422 a of slot grid 421 a of plank 410 a is parallel with slot 422 a of slot grid 422 b of plank 410 b. Slots 422 a are shown adjacent to slots 422 b, there is a gap between slots 422 b and 422 c, and slots 422 c are shown adjacent to slots 422 d. It should be appreciated that any of the slots 422 a-d can be adjacent to or separated by a gap to another pair of slots. The location of each of slots 422 a-d (e.g. positioned adjacent to a neighboring slot or with a separating gap) can be arranged to accommodate different widths of bed frame 70.

Each lateral support assembly 420 comprises a connecting member, connector 425, comprising two extensions 426 a,b shown. Connector 425 can be configured to engage a slot 422 of plank 410 a and a slot 422 of plank 410 b, thereby connecting planks 410 a, b. Depending on the width of bed frame 70, connector 425 can engage the accommodating slots 422 a-d (e.g. slots 422 a-d that accommodate bed frame's 70 with a width W_(F) between 37 inches and 72 inches).

Referring now to FIGS. 10A-D, a perspective view, a partial close-up view, and two side views of a mattress transport assembly are illustrated, respectively, consistent with the present inventive concepts. Mattress transport assembly 500 can be configured to secure (e.g. removably secure) mattress 60 and/or mattress conversion device 100 to a vehicle. In some embodiments, mattress transport assembly 500 is secured to a roof rack of the vehicle. In other embodiments, mattress transport assembly 500 is secured to the roof of the vehicle (e.g. without the need for a roof rack). Mattress transport assembly 500 can comprise an enclosure device 510 configured to receive and/or surround at least a portion of mattress 60. Mattress transport assembly 500 can further comprise one, two, or more fasteners, straps 530, configured to engage at least a portion of enclosure device 510, and at least a portion of the vehicle.

Mattress transport assembly 500 is configured to ensure mattress 60 is securely attached to a surface, such as the roof or roof rack of a moving vehicle. Currently, the market does not provide a system comprising components (e.g. bag, ratchets, ties, etc.) specifically designed to secure a mattress.

Enclosure device 510 can comprise a bag or other container. Enclosure device 510 can comprise dimensions similar to the dimensions of mattress 60 and/or mattress conversion device 100. Enclosure device 510 can further comprise a plurality of retention elements 520 fixedly attached to a surface of device 510 (e.g. an outer surface of device 510). Retention elements 520 can comprise a first end 522, a middle portion 524, and a second end 526. First end 522 and second end 526 can be fixedly attached to enclosure 510, such that middle portion 524 remains unfixed and thereby defines a passageway 528 between retention element 520 and device 510.

Straps 530 can comprise a first end 532, a middle portion 534, and a second end 536. A strap 530 can be configured to engage retention element 520, such that at least first end 532 and a portion of middle portion 534 pass through passageway 528. In some embodiments, a strap 530 passes through two or more retention elements 520. In some embodiments, each strap 530 further comprise a buckle 538, such as a ratchet buckle or a cam buckle. Buckle 538 can be configured to increase and/or decrease the tension of straps 530 when engaged with enclosure device 510. Second end 536 can be fixedly attached to buckle 538 and buckle 538 can be configured to receive at least a portion of first end 532. In some embodiments, strap 530 is configured to surround enclosure device 510 and pass under a roof rack of the vehicle, such that strap 530 secures enclosure device 510 to the roof rack. In other embodiments, strap 530 is configured to surround enclosure device 510 and pass through the windows of the vehicle, such that strap 530 secures enclosure device 510 to the roof of the vehicle.

Referring now to FIGS. 11A-C, a side view and two side perspective views of a mattress storage device including a mattress are illustrated, respectively, consistent with the present inventive concepts. Mattress storage device 600 can be configured to store a mattress 60 and/or mattress conversion device 100. Mattress storage device 600 can be configured to reduce the size of mattress 60 and/or mattress conversion device 100 therein for storage and/or transportation. Mattress storage device 600 can be further configured to provide a moisture barrier to mattress 60 and/or mattress conversion device 100 therein. In some embodiments, device 600 is disposed of after a single use. Alternatively, device 600 is configured to be reused (e.g. one or more seals or ports of device 600 are configured to be sealed and resealed at least 10 times). Mattress storage device 600 comprises a flexible enclosure, bag 610, comprising an opening 612 that includes a sealing element 614. Sealing element 614 can comprise an interlocking mechanism (e.g. a zipper) configured to seal and maintain an environment within bag 610. In some embodiments, sealing element 614 provides an airtight seal, such as seal configured to be maintained for at least 1 week, such as for at least 1 month, such as at least 6 months. Bag 610 can further comprise one or more fluid exchange ports 616 configured to facilitate the exchange of a fluid (e.g. air) between bag 610 and an external environment. Fluid exchange ports 616 can comprise a one-way valve configured to allow the passage of a fluid from within bag 610 to an external environment. In some embodiments, fluid exchange port 616 comprises a constant reverse flow check valve. In some embodiments fluid exchange port 616 comprises a cap, such as a threaded cap configured to seal port 616.

Mattress 60 can be difficult to maneuver and/or transport due to its large dimensions and/or considerable weight. It can be particularly difficult for a single person to maneuver mattress 60 by themselves. As such, the maneuvering and/or transport of mattress 60 often requires at least two people and/or a vehicle sized to accommodate the mattress (e.g. an SUV, pick-up truck). Mattress storage device 600 is configured to reduce the size (e.g. at least partially compress with the application of a vacuum as described hereabove) of mattress 60, thereby enabling a single person to maneuver mattress 60 by themselves. Additionally, mattress storage device 600 reduces the size (e.g. at least partially compress) of mattress 60 to enable mattress 60 to be placed within and/or on a vehicle that otherwise could not accommodate mattress 60. Currently, the market does not provide a mattress storage device that is large enough to receive a mattress (e.g. a queen-sized mattress). Mattress storage 600 as described herein can be configured to reduce the size (e.g. at least partially compress) of mattress 60 to aid in the maneuvering, transportation, and/or storage of mattress 60. For example, device 600 can be configured to reduce the depth of a mattress at least 50%, such as 70-80%, (e.g. a 10″ mattress reduces to approximately 2-3″), such as when sufficient vacuum is applied to fluid exchange port 616.

Bag 610 can comprise a material selected from the group consisting of: plastic; rubber; vinyl; tarpaulin; PVC; and combinations of two or more of these. For example, bag 610 comprises PVC, such as PVC with a thickness of at least 0.005″, such as approximately 0.010″. Bag 610 can comprise a material including an additive that provides protection from ultraviolet light. In some embodiments, bag 610 comprises welded seams, such as electrically or ultrasonically welded seams. Bag 610 can slidingly receive at least one of mattress 60 and/or mattress conversion device 100 via opening 612 and can be sealed within bag 610 via sealing element 614. Fluid within bag 610 (e.g. air or other fluid within mattress 60 and/or mattress conversion device 100) can be removed via fluid exchange ports 616. In some embodiments, a vacuum source (e.g. a vacuum pump such as a liquid cooled rotary vane vacuum pump producing up to 9 cfm of flow) is connected to fluid exchange port 616 to expedite the removal of the fluid within bag 610. Removal of the fluid from bag 610 can reduce the size (e.g. volume) of the contents within (e.g. mattress 60 and/or mattress conversion device 100). In some embodiments, bag 610 is configured to withstand an applied vacuum up to −14.7 psig (e.g. to achieve maximum compression of mattress 60 and/or mattress conversion device 100 within bag 610). Fluid can be reintroduced into bag 610 (e.g. mattress 60 and/or mattress conversion device 100) by unlocking or otherwise releasing sealing element 614 to open bag 610.

Referring now to FIG. 12, a flow chart of a method for processing a previously manufactured mattress to produce a new mattress is illustrated, consistent with the present inventive concepts. Method 1000 can comprise recycling or other processing of a previously manufactured mattress to produce a new mattress 60′ and/or one or more portions of a mattress conversion device 100. Previously manufactured mattress 50 can comprise a foam core surrounded by a fire-retardant cover, which are collectively surrounded by an outer cover.

Currently, mattress retailers manufacture their mattresses adhering to a common process: the retailer engages a contract manufacturer; the retailer selects the mattress materials (e.g. fabric, foam, etc.); and the retailer compensates the manufacturer to produce the mattress. A majority of mattress retailers offer a trial period (e.g. a 100 nights trial period) for customers to use and test the mattress, thereby allowing the customer to return the mattress if they are not satisfied with the mattress; approximately 10% of customers take advantage of the trial period. Mattresses which are returned to the retailers generate excess waste that results in additional strain on landfills, donation centers, and recyclers. Method 1000 as disclosed herein is configured to refurbish the used and/or returned mattresses, thereby alleviating the excess waste commonly attributed to mattresses.

In Step 1010, an existing mattress 50 is obtained. Mattress 50 can be obtained from a manufacturing facility, a disposal facility, a recycling facility, and/or a storage facility. Mattress 50 can be obtained from the manufacturer of the mattress. In some embodiments, mattress 50 comprises a mattress that was returned by a customer (e.g. to the manufacturer of the mattress, their distributor, or otherwise), such as a mattress returned following a trial period. Mattress 50 can comprise a mattress of any size, including a California king, a king, a queen, a full, an extra-long twin, a twin.

In Step 1020, an optional step can be performed in which mattress 50 is tested for defects and/or other undesirable features. Mattress 50 can be tested for undesirable features selected from the group consisting of: splitting seams; structural failure; indentations; irregular bunching; undesired wear and tear; stains; odors; and combinations of two or more of these.

In Step 1025, mattress 50 is evaluated based on a defect threshold. In some embodiments, mattress 50 is above the defect threshold, such that mattress 50 comprises one or more defects and/or other unfavorable features that prevents mattress 50 from being processed further according to Method 1000. In this embodiment, mattress 50 can be discarded or further processed (e.g. repaired) in Step 1027. In other embodiments, mattress 50 is below the defect threshold, such that mattress 50 does not comprise sufficient defects and/or other significant unfavorable features. In this embodiment, mattress 50 is processed further according to Method 1000.

In Step 1030, mattress 50 is disassembled into two or more portions. For example, mattress 50 can be dissembled into three portions comprising an outer cover, a fire retardant cover, and a foam core. In this embodiment, the outer cover of mattress 50 is removed to expose the fire retardant cover thereunder and the fire retardant cover of mattress 50 is removed to expose the foam core thereunder.

In Step 1040, at least one portion of mattress 50 processed in STEP 1030 is used to form at least a portion of a new mattress, mattress 60′. In some embodiments, at least 5% (e.g. 5% by weight or volume) of mattress 50 is used to produce new mattress 60′. For example, at least 10%, at least 20%, at least 35%, and/or at least 50% of mattress 50 can be used to produce new mattress 60′. In some embodiments, at least 75% of mattress 50 is used to produce new mattress 60′. For example, the foam core of a mattress 50 can be cut into two or more portions, such that the foam core is cut to achieve a desired size for mattress 60′. In some embodiments, mattress 50 comprises a king mattress of which its foam core is cut to comprise the dimensions of a smaller-sized mattress 60′, such as to create a mattress 60′ comprising a full mattress. In other embodiments, mattress 50 comprises a queen mattress of which its foam core is cut to comprise the dimensions of a smaller-sized mattress 60′, such as to create a mattress 60′ comprising an extra-long twin mattress. In other embodiments, mattress 50 comprises a mattress (e.g. a king or queen sized mattress) of which its foam core is cut to create at least a portion of mattress conversion device 100 (e.g. to create top layer 110, base layer 121, and/or base portion 120).

In Step 1050, an optional step can be performed in which at least one portion of mattress 50 processed in STEP 1030 and/or STEP 1040 is recycled (e.g. according to the appropriate waste disposal guidelines). For example, at least one of the unused portions of the foam core in STEP 1040 can be recycled accordingly. As another example, at least one of the outer cover or fire retardant cover in STEP 1030 can be recycled accordingly. In some embodiments, at least 5%, at least 10%, and/or at least 20% of mattress 50 is recycled.

In Step 1060, comprising an optional step, at least one portion of mattress 50 processed in STEP 1030 and/or STEP 1040 can be discarded according to the appropriate waste disposal guidelines. For example, at least one of the unused portions of the foam core in STEP 1040 can be discarded accordingly. As another example, at least one of the outer cover or fire retardant cover in STEP 1030 can be discarded accordingly. In some embodiments, less than 90% of mattress 50 is discarded, such as less than 80% or less than 70%.

Referring now to FIGS. 13A and 13B, a close-up perspective view of a bracket of a support device and a top perspective view of the support device are illustrated, respectively, consistent with the present inventive concepts. Frame conversion device 300 can comprise a plurality of support elements, brackets 710. Brackets 710 can be configured to engage a portion of bed frame 70 and can be configured to slidingly receive a portion of at least one support structure, plank 720. Planks 720 can be configured to engage a portion of at least one support structure, plank 730. Planks 720,730 can comprise a rigid material and can be configured to provide a support force to mattress 60 and/or mattress conversion device 100 placed thereupon.

As shown in FIG. 13A, each bracket 710 comprises two U-shaped supports, loops 711 a, b, connected by two extension members, connectors 712 a,b. Connectors 712 a,b can be configured to engage a top portion of rail 72, such that loops 711 a-b extend below a bottom portion of rail 72 thereby forming an opening 713. Opening 713 is configured to slidingly receive a portion of plank 720.

As shown in FIG. 13B, each rail 72 a,b of bed frame 70 can receive at least one bracket 710, such that a bracket 710 on rail 72 a can be positioned parallel to a bracket 710 on rail 72 b. Each bracket 710 receives at least a portion of plank 720. Plank 720 can comprise a length L_(P1) that is greater than the width W_(F) of bed frame 70, as shown. A plank 730 can be removably attached to at least a portion of plank 720 via an attachment assembly 735. Attachment assembly 735 can be constructed and arranged similar to attachment assembly 330 described hereabove in reference to FIGS. 6, 6A, and 6B. Plank 730 can comprise a length L_(P2) that is greater than or equal to the length L_(F) of bed frame 70.

Referring now to FIGS. 14A-C, a series of component configurations of a manufacturing process for repurposing previously manufactured mattresses is illustrated, consistent with the present inventive concepts. In accordance with the present inventive concepts, one or more previously manufactured mattresses 50 can be repurposed (e.g. modified) to produce one or more new mattresses 60′. The process of FIGS. 14A-C can be configured to produce at least one more new mattress 60′ than the number of previously manufactured mattresses 50. In some embodiments, such as are described herein, mattresses 60′a, 60′b, and/or 60″ can comprise standard mattress sizes (e.g. mattresses with the same and/or different standard lengths and widths), and mattresses 50 can comprise standard mattress sizes (e.g. mattresses larger than the standard size of mattresses 60′a, 60′b, and/or 60″). In some embodiments, the process is configured to produce mattresses 60′a, 60′b, and/or 60″ with less than 25% waste of each mattress 50, such as when less than 20%, 15%, or 10% of each mattress 50 is discarded. In the illustrated example, two previously manufactured queen mattresses, mattresses 50 a and 50 b, are modified and reassembled to form three twin XL mattresses, mattresses 60′a, 60′b, and 60″.

In FIG. 14A, the cut locations of mattresses 50 a and 50 b are illustrated. In the embodiment shown, mattresses 50 a and 50 b comprise the same size mattress, however similar processes with varying mattress sizes should be considered within the scope of the present inventive concepts. Mattresses 50 a, b can comprise a width W_(M), such as a width of 60 inches for a standard queen size mattress. Cut lines CL are shown bisecting mattresses 50 a, b, into portions 51 a, b and 52 a,b. Portions 51 a, b can each comprise a width W_(F), such as a width of 38 inches for a standard twin XL mattress. Portions 52 a,b can each comprise a width W_(P), such that width W_(P) is less than a standard mattress width (e.g. 22 inches in the illustrated embodiment).

In FIG. 14B, mattresses 60′a and 60′b are shown comprising portions 51 a and 51 b, respectively. Portions 51 a and 51 b can be converted to mattresses 60′a and 60′b, respectively, in a process similar to Step 1040 of Method 1000 described in reference to FIG. 12 herein. Each mattress 60′a,b comprises a width WF as shown. Mattress 60″ is shown comprising portions 52 a and 52 b. Portions 52 a and 52 b can be bonded together, for example, glued together to form mattress 60″. In some embodiments, a waste portion of each portion 52 a,b, waste portions 53 a,b, respectively can be trimmed such that mattress 60″ comprises a width W_(F) equal to a standard mattress width. In some embodiments, waste portions 53 a,b each comprise a width W_(W). In the illustrated embodiments, W_(P) is equal to 22 inches, and W_(W) is equal to3 inches, such that W_(F) of mattress 60 is equal to 38 inches, the width of a standard twin XL mattress. In some embodiments, the width W_(W) is less than 25% of the width of W_(M), such as less than 20%, less than 15%, or less than 10%.

In FIG. 14C, mattress 60″ is illustrated with a top layer, layer 65. Layer 65 can be similar to top layer 110 described herein. Layer 65 can be bonded (e.g. glued together) to the top surfaces of portions 52 a,b, such as to provide a seamless sleeping plane (e.g. a seamless top surface of mattress 60″). In some embodiments, portions 52 a,b each comprise a depth D_(M) of between 6 inches and 10 inches. In some embodiments, top layer 60 comprises a depth D_(T) of between 2 inches and 3 inches.

The above-described embodiments should be understood to serve only as illustrative examples; further embodiments are envisaged. Any feature described herein in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. 

1. A sleep system comprising: a mattress conversion device comprising: a base layer; one or more side portions; and a cavity defined by the base layer and the one or more side portions; and a mattress; wherein the mattress conversion device is configured to slidingly receive the mattress. 2.-51. (canceled) 